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NASA NTRS2020

Efficient Thermal Management for Sampling Arm Actuators

An electric actuator incorporating novel features for thermal management is designed and analyzed. Reducing intra-actuator thermal resistance is not only beneficial for cold missions (helping to pre-heat the gearbox) but can also enable high power applications in benign environments. The proposed design increases the thermal conductance between the motor windings and the motor casing by at least two orders of magnitude over the state of practice actuator designs. The design leverages Additive Manufacturing (AM) to integrate a complex 3 dimensional Oscillating Heat Pipe (OHP) directly within the actuator structure. A baseline actuator without this thermal management feature was fabricated. Testing was conducted to evaluate the temperature difference between actuator components at a range of motor winding heat dissipations. An analysis of a proposed revised design incorporating OHPs into the input structure indicated an increase in the effective thermal conductivity of 8 and 22 times for the nominal and start-up modes respectively. In addition, the thermal conductance between the windings and the input structure is increased by a factor of 90, and the thermal conductance between the windings and the gear assembly is increased by a factor of 200 with the proposed design.

Odagiri, Kimihide↗

NASA NTRSDate not supplied

Rapid Development of Instrument Thermal Models: Perspectives and Guidelines from NASA Goddard’s Instrument Design Laboratory

The Instrument Design Laboratory (IDL), part of NASA Goddard Space Flight Center’s Integrated Design Center (IDC), is a concurrent and collaborative environment which allows for rapid development of science instrumentation concepts within the span of less than two weeks. Science goals set by a Principal Investigator from government, industry or academia are translated into engineering requirements, from which a team of engineers spanning multiple disciplines use an established study process and a suite of analysis tools to work towards an instrument point design. As part of this process, a staff thermal engineer is tasked with designing a thermal control system which meets all incoming thermal requirements, while iterating real-time with other subsystems to ensure compatibility and functionality as a completed system. Thermal engineers on spaceflight projects typically have weeks or months to develop thermal models. However, the severe time limitation in this conceptual study setting makes thermal design particularly difficult, as rapid thermal modeling solely over the span of a few days is required to develop the instrument thermal design and understand the performance over its intended mission, especially if the instrument concept contains multiple thermal challenges such as dynamic environments or high heat dissipating components. In this paper, the authors provide a condensed guide for the most efficient ways to develop thermal models and conduct thermal analysis within the span of one-to-two weeks, as informed by decades of design experience and best practices in the IDL. The authors also focus on quick methods for determining worst-case thermal environments, deciding which modeling details are essential at this early phase, and quantifying the engineering resources necessary for thermal control. This paper concludes with specific thermal design tips for different instrument types across the electromagnetic spectrum.

Kan Yang↗

NASA NTRSDate not supplied

Feasibility of Micro-Multilayer Multifunctional Electrical Insulation (MMEI) System for High Voltage Applications

The newly patented micro-multilayer multifunctional electrical insulation (MMEI) system was developed for future electric aircraft applications which critically require lightweight but high voltage (HV), high temperature, and corona or partial discharge (PD) resistant insulation. During the initial development stages, the concept and practicability of the MMEI system were successfully validated with its exceptionally high dielectric breakdown voltages. The multilayer structures were optimized in terms of material type, individual layer thickness, and overall layer configuration along with potential mechanisms identified for its superior performance. Subsequently, scalability, manufacturability, and commercial applicability of the MMEI system were demonstrated with the 1 meter long, 3-phase HV, high power (HP) bus bar prototypes. Two prototypes, one with the conventional SOA insulation system including Mica sheet and the other with an optimized MMEI, were designed, fabricated, and tested successfully. Both prototypes passed both HiPot and PD tests up to the highest test voltage available, 15 kVAC, although the latter showed a slight increase in PD activities at 12.5 kV. However, the prototype with MMEI was 15% lighter or 12% thinner than the other one. Current efforts to significantly enhance the PD resistance of the MMEI system by employing semiconductive shielding layers, which can be also multifunctional, e.g., electromagnetic interference shielding, moisture blocking, heat dissipation, for various HV applications are also discussed in this paper.

Novel Electrical Insulation↗

NASA NTRSDate not supplied

Development and Application of a Novel Calorimetry Technique for the Study of Lithium-Ion Cell Thermal Runaway

Lithium-ion battery technology is widely used and is attractive due to demonstrated specific energies in the 200-300 W-hr/kg range. The excellent, mass-efficient energy storage capability of lithium-ion batteries has led to their use on many aerospace platforms. However, lithium-ion batteries can exhibit thermal runaway behavior wherein stored electrochemical energy is released rapidly as a result of thermal or mechanical failure, electrochemical abuse, internal or external short circuiting. A single cell undergoing thermal runaway within a battery has the potential to induce thermal runaway in adjacent cells if heat dissipation is not properly managed and can result in a catastrophic failure of the battery. Designing batteries that are resistant to thermal runaway propagation requires an understanding of, not only, total energy yield but also the means by which that energy is liberated from the cell. While Accelerating Rate Calorimetry and other techniques provide total thermal runaway energy yield, they do not provide the fractional breakdown of energy liberated via conduction through the cell casing from that which is vented from the cell as hot gases and effluents. Such data are needed to inform battery thermal design and analysis. To measure the total energy yield, the fraction conducted through the cell casing, and the fraction lost due to gases and effluents, NASA developed Fractional Thermal Runaway Calorimetry (FTRC). Two calorimeters have been developed and demonstrated, the Small-format- and Large-format Fractional Thermal Runaway Calorimeters (S-FTRC and L-FTRC, respectively). The technique has been successfully applied to small- and large-format cells (2.4-3.5 Ah and >100 Ah capacity, respectively) and has given new insights into Li-ion cell thermal runaway. Development of the calorimeters is discussed and results from the initial thermal runaway testing campaigns are presented.

Lithium-Ion Cell↗

NASA NTRSDate not supplied

Feasibility of Micro-Multilayer Multifunctional Electrical Insulation (MMEI) System for High Voltage Applications

Novel Electrical Insulation↗

NASA NTRS2024

Flexural Fatigue Testing and Qualification of Hybrid PAN-pitch Composite Materials with High Through-Thickness Thermal Conductivity

Carbon-fiber-reinforced polymers (CFRPs) considered for motor components within future electric vertical takeoff and landing (eVTOL) vehicles require not only a high strength-to-weight ratio but also a high through-thickness thermal conductivity (TC) to dissipate heat. Previously, CFRPs incorporating pitch CF interleaves demonstrated an increased through-thickness TC relative to the baseline composite, but the effect on flexural fatigue life was not evaluated. For this work, T700S/TC275–1 braided carbon fiber/epoxy prepreg baseline (no interleave), YSH–60A pitch interleave, and YS–80A pitch interleave configurations were tested for fatigue life. A combination of ASTM International Standards D7264 and D3479 were used to develop a reliable testing method. An Instron® (Illinois Tool Works Inc.) 8501 servohydraulic system with a fatigue test fixture was set up with a 16:1 span:thickness ratio, load ratio R set to 0.1, and frequency of 4 Hz. High-cycle fatigue testing was completed, and it was found that YSH–60A interleave performed slightly better than YS–80A below 100,000 cycles but showed no differences above 100,000 cycles. In all cases, the baseline CFRP had superior fatigue life performance both in terms of stress handled and total cycles to failure. These fatigue testing data will inform future use of hybrid CFRP materials by highlighting the tradeoff between increased through-thickness TC and fatigue life. Testing guidelines, equipment, and parameters for static and fatigue tests were successfully outlined for CFRPs.

composites↗

NASA NTRS2025

The Shape Effect: Influence of 1D and 2D Boron Nitride Nanostructures on the Radiation Shielding, Thermal, and Damping Properties of High-Temperature Epoxy Composites

In space exploration, lightweight multifunctional materials capable of shielding neutron radiation, dissipating heat, and providing damping are essential. Polymer composites reinforced with boron nitride (BN) nanomaterials—specifically one-dimensional boron nitride nanotubes (BNNTs) and two-dimensional boron nitride nanoplatelets (BNNPs)—offer promising solutions. This study investigates how BN nanomaterial morphology influences the performance of high-temperature (HT) epoxy composites. We developed ultralightweight, three-dimensional BN foams comprising 1D BNNTs, 2D BNNPs, and hybrid 1D BNNT/2D BNNP structures via freeze-drying, then infiltrated them with HT epoxy to form dense composites. The BNNT foam exhibited the highest neutron radiation shielding, with a mass absorption coefficient of 26.64 cm2 g −1 , outperforming the hybrid foam (18.18 cm 2 g −1 ) and the BNNP foam (11.12 cm 2 g −1 ). A similar trend was observed in the HT epoxy composites; incorporating these foams at least doubled the mass absorption coefficient compared to the neat polymer. In terms of thermal conductivity, the BNNT/BNNP foam-epoxy composite achieved the highest value of 0.34 W m −1 K −1 , a 2.13-fold increase over neat HT epoxy. The BNNT/BNNP foam-epoxy composites also improved by 1.88 and 1.75 times, respectively. Mechanical testing revealed that BNNP foams withstood the highest loads during nanoindentation (3.53 kN), followed by BNNT/BNNP foams (1.93 kN) and BNNT foams (1.56 kN). All BN foam-epoxy composites exhibited enhanced damping properties, with tan δ increasing by at least 30 % compared to neat HT epoxy. These findings elucidate the impact of BN nanomaterial morphology on the multifunctional performance of HT epoxy composites, offering insights for developing high-performance, tailorable materials for demanding environments.

Kazue Orikasa↗

DOE OSTI2020

Hygroscopic cooling tower for waste water disposal

In various embodiments, the present invention relates to heat dissipation systems including a hygroscopic working fluid integrating waste water as makeup water. The present invention also relates to methods of using the same. The present invention also relates to hygroscopic cooling systems adapted to dispose of waste water by combining the waste water with a hygroscopic working fluid, precipitating impurities and evaporating the remaining water.

Martin, Christopher Lee↗

DOE OSTI2021

Thermal and Mechanical Design of a High-Voltage Power Electronics Package: Preprint

Thermal and mechanical design aspects of a power electronic package with 5-kV GaN devices are presented. Through finite element analyses, the impact of different cooling configurations and device location on the thermal performance and reliability of the package was investigated. It was found that placing the devices closer to the direct-bond-copper substrate as opposed to a centered approach in the proposed double-sided-cooling configuration resulted in improved heat dissipation. This approach also reduced the total number of attachment layers, thereby likely improving the reliability of the package. Furthermore, simulations revealed that the device location had a negligible impact on the thermomechanical behavior of the attachment layers, as they are more prone to the local coefficient of thermal expansion mismatch.

27 ARPA - Advanced Research Projects Agency-Energy↗

DOE OSTI2021

Method of manufacturing a complex product by an additive process

A method of producing a complex product includes designing a three dimensional preform of the complex product, creating a three dimensional preform of the complex product using the model, depositing a material on the preform, and removing the preform to complete the complex product. In one embodiment the system provides a complex heat sink that can be used in heat dissipation in power electronics, light emitting diodes, and microchips.

Pascall, Andrew J.↗

DOE OSTI2023

Functionally graded thermal vias for inductor winding heat flow control

Embodiments of the disclosure relate to apparatuses for enhanced thermal management of an inductor assembly using functionally-graded thermal vias for heat flow control in the windings of the inductor. In one embodiment, a PCB for an inductor assembly includes a top surface and a bottom surface. Two or more electrically-conductive layers are embedded within the PCB and stacked vertically between the top surface and the bottom surface. The two or more electrically-conductive layers are electrically connected to form an inductor winding. A plurality of thermal vias thermally connects each of the two or more electrically-conductive layers to a cold plate thermally connected to the bottom surface. A number of thermal vias thermally connecting each electrically-conductive layer to the cold plate is directly proportional to a predetermined rate of heat dissipation from the electrically-conductive layer.

Dede, Ercan↗

DOE OSTI2023

Hygroscopic cooling tower for waste water disposal

Martin, Christopher Lee↗

DOE OSTI2023

A 4 x 4 SiPM Sensor Array with Fast Preamplified Output Engineered for the PWO Detectors of the EIC EEEMCAL

The PbWO4 scintillation detectors for the Electron-Ion Collider Electron Endcap Electromagnetic Calorimeter (EEEMCAL) cannot use vacuum photomultipler tubes due to the high magnetic field environment. We are presenting a readout solution with a 4 x 4 SiPM array directly coupled to a preamplification and summing stage. A second amplification stage with variable gain and offset adjustments is also included in the compact electronics module. The integrated power supply feeds the signal processing chain and the adjustable bias control. The parameter settings are saved locally on a EEPROM and are adjustable via the integrated communication interface through USB or RS485. The design was optimized to maximize signal collection energy resolution, for fast timing and wide dynamic range while keeping a small footprint with low power consumption and heat dissipation. The output response is fast enough to meet the 100 ? 200 ns digitization gate requirements for the detector. The electronics assembly requires no active cooling and includes a temperature sensor and a gain compensation of thermal variations which are important features for stable operation in large scale detector structures. A detector prototype was constructed with 20 mm x 20 mm x 200 mm PWO crystals affixed with individual SiPM array readouts and arranged in a 3 x 3 array. This detector was tested at the Thomas Jefferson National Accelerator Facility with 5GeV positrons. We will present the results of these detector characterization measurements.

Philip, O.↗

DOE OSTI2024

High Fidelity Simulations of Air-Cooled Reactor Cavity Cooling System

High Temperature Gas Reactor (HTGR) designs incorporate passive safety systems (e.g., the Reactor Cavity Cooling System [RCCS]) that utilize natural principles to manage heat dissipation from the reactor pressure vessel (RPV) during accidents or routine shutdowns. The industry community is experiencing a pressing need for advanced simulation tools that can accurately assess the performance of these types of systems. In the literature, a knowledge gap exists concerning high-fidelity data for the RCCS, and this gap is one of the areas of focus of the present study. This research focuses on a specific RCCS designed for General Atomics' Modular High-Temperature Gas Reactor (GA-MHTGR). Experimental studies on a scaled version (can be seen in Figure 1) of the air-cooled RCCS used in GA-MHTGR were conducted by the University of Wisconsin-Madison (UW-Madison). This work contributes to a broader initiative aimed at establishing a numerical benchmark based on the UW-Madison experiments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Experimental Investigation on Cooling performance of A Thermoelectric Freezer

Thermoelectric heat pumps (TEHPs) have found widespread use in the electronics cooling industry and portable refrigerators. However, there has been a lack of extensive research on the application of TEHPs in low-temperature refrigeration settings. To address this gap, various configurations of TEHPs were fabricated to assess their suitability for freezer applications. Key parameters such as cooling capacity and system performance of the TEHPs were crucial in evaluating these configurations. Three configurations, each with different numbers of cooling units and fan arrangements, were tested using a 300-liter freezer prototype under typical room conditions (21°C). A cooling unit is comprised of two-stage thermoelectric modules, an aluminum plate fin heat exchanger sink with fans positioned either on top or directing airflow through the center, and a cooling block with circulating icy water for heat dissipation. Across all configurations, the minimum temperature inside the freezer cabinet reached -16.0°C. The cooling capacity peaked at 74.7 W, with the thermoelectric coefficient of performance (COP) reaching a maximum of 0.45. System COP ranged from 0.23 to 0.28. Minimum TE power consumption was recorded at 138.8 W, with TE system power consumption at 174.4 W, indicating feasibility for practical residential freezer applications. This investigation lays the foundation for integrating TE freezers with ice thermal storage systems.

Hu, Yifeng↗

DOE OSTI2024

Transformer with integral inductor

In accordance with one embodiment is a transformer with a core comprising a perimeter portion and central intervening portion. The central intervening portion is separated from the perimeter portion by air gaps, creating an opening on either side of the intervening portion. A primary winding and secondary winding are wound around the central intervening portion of the core. The primary winding is capable of electromagnetic interaction with the secondary winding. A pair of ferrite members arranged outward from a central axis of the central intervening portion of the core and increases a series inductance with the primary winding. In accordance with another aspect of the disclosure, each ferrite member may have an air gap associated with the core to facilitate heat dissipation from the transformer.

Rastogi, Sagar K.↗

DOE OSTI2021

Microbubble dynamics and heat transfer in boiling droplets

Dissipating large heat fluxes from a surface is critically important in numerous industrial and natural applications. Boiling based spray cooling and surface texturing are two of the most promising methods being investigated to address this problem. Although our understanding on these topics has significantly improved over past decades, critical gaps remain in the knowledgebase stymieing the realization of their full potential. As an example, while bubble growth in pool boiling have been investigated in detail, comparatively little is known about how the bubbles evolve inside boiling drops. In the present work, we have investigated for the first time, the microbubble dynamics inside water droplets boiling on superhydrophilic textured substrates using high-speed X-ray phase contrast imaging (XRPCI). Our observations show that the transient bubble density variation follows similar characteristics irrespective of the texture spacing at a given surface temperature. For an example microstructure, we found that the number of discrete bubbles on the surface decreases as temperature is increased although their growth rate increases. Here, we observe that bubble growth is highly non-uniform during the lifetime of a drop on the surface. Initially, bubbles grow under diffusion-limited regime, but at later times they grow as ~t 1.45 due to combined effects of coalescence and evaporation. In some conditions, we found that bubbles shrink dramatically af- ter the initial growth spurt presumably due to severe quenching of the surface, and migration of bubbles on the surface. Using the bubble sizes, for the first time we analyzed the heat flux removed by a single bubble and also by all the bubbles at a given time. We find that the highest dissipation through latent- heat component (~600 W/cm 2 ) occurs just in the beginning and thereafter it decreases. We expect that our findings and the analysis would guide further work on the topic and will aid in the overarching goal of engineering surfaces that are more efficient in boiling heat transfer.

42 ENGINEERING↗

NASA NTRS1992

Two dimensional PIC simulations of plasma heating by the dissipation of Alfven waves

Two dimensional plasma particle simulations of the evolution of large amplitude circularly polarized Alfven waves propagating parallel to the magnetic field show that the waves decay via both one- and two- dimensional parametric decay instabilities. For parameters studied, one-dimensional processes dominate the simulations, but two-dimensional decay processes, including the recently predicted filamentation instability are also observed. The daughter waves generated by the parametric decay are primarily damped by the ions, leading to ion heating. The parametric decay processes efficiently convert the ordered fluid ion motion in the Alfven wave into ion thermal energy. These processes may be important for the dissipation of Alfven waves in the solar wind, the corona and other space plasma environments. The computations were performed on the Intel Touchstone parallel supercomputer.

Liewer, P. C.↗